Skip to main content
SpringerLink
Log in

Scientific, technological, and economic aspects of rapid tooling by electric arc spray forming

  • Reviewed Papers
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

For the last seven years, Oxford University and Ford Motor Company personnel have been researching jointly the development of the large-scale spray forming of steel tooling capable for use in mass production, particularly for the pressing of sheet metal in automotive applications. These investigations have involved: the comprehensive microstructure and property studies, modeling of shape evolution and heat flow, realtime feedback control of tool temperature to eliminate tool distortion, high-speed imaging and particle image velocimetry of droplet deposition on three-dimensional (3D) shapes, testing of full-scale tools for different applications in the production environment, and detailed studies of the cost and time savings realized for different tooling applications. This paper provides an overview of the scientific and technical progress to date, presents the latest results, and describes the current state-of-the-art. Many of the insights described have relevance and applicability across the family of thermal spray processes and applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. B. Xu, X. Liu, S. Ma, and Z. Chen, The Experimental Study on Arc Sprayed Mouldmaking for Plastic Products,Thermal Spray: Meeting the Challenges of the 21st Century (Nice, France), May 25–29, 1998, C. Coddet, Ed., ASM International, 1998, p 1039–1042

  2. M. Statham, E. Hammett, B. Harris, R.G. Cooke, R.M. Jordan, and A. Roche, Net-Shape Manufacture of Low-Cost Ceramic Shapes by Freeze-Gelation,J. Sol-Gel Sci. Technol., 1998,13, p 171–173

    Article  CAS  Google Scholar 

  3. A.P. Newbery, P.S. Grant, A.R. Roche, R.M. Jordan, and T. Carr, The Electric Arc Spray Manufacture of Rapid Production Tooling: A Case Study,Thermal Spray: Meeting the Challenges of the 21st Century (Nice, France), May 25–29, 1998, C. Coddet, Ed., ASM International, 1998, p 1223–1228

  4. S. Hoile, T. Rayment, and P.S. Grant, Phase Transformations and Control of Residual Stresses in Thick Spray Formed Steel Shells,Metall. Mater. Trans. B, 2004,35B, p 1113–1122

    Google Scholar 

  5. P.D.A. Jones, S.R. Duncan, T. Rayment, and P.S. Grant, Optimal Robot Path for Minimizing Thermal Variations in a Spray Deposition Process,IEEE Trans. Control Sys. Technol., accepted for publication

  6. P.S. Grant, W.T. Kim, B.P. Bewlay, and B. Cantor, The Monitoring of Deposit Surface Temperatures During Spray Forming by Infrared Thermal Imaging,Scr. Met., 1989,23, p 1651–1656

    Article  CAS  Google Scholar 

  7. P.D.A. Jones, S.R. Duncan, T. Rayment, and P.S. Grant, Control of Temperature Profile for a Spray Deposition Process,IEEE Trans. Control Sys. Technol., 2003,11, p 656–667

    Article  Google Scholar 

  8. A.P. Newbery, P.S. Grant, and R.A. Neiser, The Velocity and Temperature of Steel Droplets During Electric Arc Spraying,Surf. Coatings Technol., 2005,195, p 91–101

    Article  CAS  Google Scholar 

  9. T. Rayment and P.S. Grant, Modelling the Heat Flow in Spray Formed Steel Shells for Tooling Applications,Mater. Trans. B, accepted for publication

  10. A.P. Newbery and P.S. Grant, Droplet Splashing and Microstructure in Electric Arc Spraying,J. Thermal Spray Technol., 2000,9, p 250–258

    Article  CAS  Google Scholar 

  11. A.P. Newbery, T. Rayment, and P.S. Grant, A Particle Image Velocimetry Investigation of In-Flight and Deposition Behaviour of Steel Droplets During Electric Arc Spray Forming,Mater. Sci. Eng. A, 2004,383, p 137–145

    Article  Google Scholar 

  12. Z. Djuric and P.S. Grant, Two Dimensional Simulation of Liquid Metal Spray Deposition onto a Complex Surface II: Splashing and Redeposition,Model. Simul. Mater. Sci. Eng., 2001,9, p 111–127

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Materials, Oxford University, Parks Rd, OX1 3PH, Oxford, U.K.

    P. S. Grant

  2. Department of Engineering Science, Oxford University, Parks Rd, OX1 3PJ, Oxford, U.K.

    S. R. Duncan

  3. Scientific Research Laboratory, Ford Motor Co., 48124, Dearborn, MI

    A. Roche & C. F. Johnson

Authors
  1. P. S. Grant
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S. R. Duncan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Roche
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. C. F. Johnson
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P. S. Grant.

Additional information

This article was originally published inBuilding on 100 Years of Success, Proceedings of the 2006 International Thermal Spray Conference (Seattle, WA), May 15–18, 2006, B.R. Marple, M.M. Hyland, Y.-Ch. Lau, R.S. Lima, and J. Voyer, Ed., ASM International, Materials Park, OH, 2006.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Grant, P.S., Duncan, S.R., Roche, A. et al. Scientific, technological, and economic aspects of rapid tooling by electric arc spray forming. J Therm Spray Tech 15, 796–801 (2006). https://doi.org/10.1361/105996306X1468794

Download citation

  • Received:

  • Revised:

  • Issue Date:

  • DOI: https://doi.org/10.1361/105996306X1468794

Keywords

Search

Navigation